Apparatus and method for forming flanged openings

ABSTRACT

An apparatus and method for creating a flange around a preformed opening in a wall of a tubular member. The apparatus includes an elongated guidance housing adapted to fit within the tubular member. An elongated presser having at least one pressing surface is slidably received within the guidance housing. A punch member is located adjacent the pressing surface within the guidance housing. The punch member is sized to fit at least partially through a side opening in the guidance housing and at least partially through the preformed opening. When the presser is advanced relative to the guidance housing, the pressing surface to urges the punch-through the side opening and through the preformed opening. The movement of the punch thereby forms an outwardly upstanding annular flange extending around the preformed opening in the tubular member.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to machining processes. In particular, the present invention relates to an apparatus and method for forming flanged openings in objects where access to certain areas may be difficult or undesired.

[0002] In typical machining processes, openings are formed in metal or plastic objects using techniques such as drilling or punching. These techniques are most often performed by orienting the object to be machined perpendicularly to a drill bit or punch.

[0003] Due to particularities of some processes, however, openings may need to be formed on objects where normal access by a drill bit or punch is not possible. For example, a relatively small opening may need to be formed in a distal end of a long section of sealed pipe after connection to another sealed object. Because of the nature of this configuration, it may not be possible to introduce a tool to drill the opening after the connection is made. The solution to this problem would typically involve the steps of drilling concentric openings in each object before connection. The numerous steps involved in drilling the individual objects and precisely aligning them together for connection may prove difficult, expensive and time-consuming for the manufacturer.

[0004] Some applications require formed openings to include a short flange or rim annularly defined around a round opening. This flange is used to facilitate welding of the object to another object and to ensure a complete seal around the opening after the weld. An example of such an application is the configuration of a 0.5-inch manifold pipe used in automobile applications. To manufacture the proper configuration, is necessary to attach threaded joints to the sidewalls of a narrow, bent section of the thin aluminum tubing. A drilled, round opening is formed in the sidewall concentrically with the joint attachment point to allow airflow through the sidewall and into the joint.

[0005] The attachment of the threaded joints to the pipe requires strong, airtight welds nearly normally to the sidewalls of the tubing. To ensure the strength and integrity of the welds, it is preferable to form an outwardly facing, annular flange around the opening in the sidewall before attachment of the threaded joint. To best form this joint, it is preferable or desired to machine the flange from the interior side of the tubing in order to ensure a uniform flange rim that faces outwardly in a desired direction. However, as in the hole-forming processes described above, access to the interior of the tubing is difficult for conventional tooling. Thus, the flange must be formed by inserting a punch tool from the exterior side of the tubing into a pre-formed, drilled opening in the sidewall. The tool is expanded within the opening and is withdrawn from the tube with force, thereby bending the rim of the opening slightly toward the exterior of the pipe.

[0006] This rim-forming process has serious shortcomings. Most significantly, the withdrawal of the tool from the hole does not produce a uniform flange, but rather a flange that is uneven and includes cracks caused by fatigue of the surrounding metal. The poor quality of the flange can seriously compromise the weld or brace used to attach the threaded joint to the tubing. Other methods have been utilized, such as welding exterior flanges around the tubing, but these operations are very costly and difficult to perform.

[0007] Therefore, there is a need for a tooling operation and apparatus for forming openings and flanges in objects where access to the object from the exterior is difficult or unpreferred.

SUMMARY OF THE INVENTION

[0008] To alleviate the shortcomings noted above and in the prior art, an apparatus and method are provided herein to create a flange around a preformed opening in a wall of a tubular member. In one aspect of the present invention, the apparatus includes an elongated guidance housing adapted to fit within the tubular member. An elongated presser having at least one pressing surface is slidably received within the guidance housing. A punch member is located adjacent the pressing surface within the guidance housing. The punch member is sized to fit at least partially through a side opening in the guidance housing and at least partially through the preformed opening. When the presser is advanced relative to the guidance housing, the pressing surface to urges the punch through the side opening and through the preformed opening. The movement of the punch thereby forms an outwardly upstanding annular flange extending around the preformed opening in the tubular member.

[0009] In another aspect of the invention, an apparatus for forming an opening in a wall of a tubular member includes an elongated guidance housing adapted to fit within the tubular member. The guidance housing defines a hollow interior space and at least one side opening. An elongated presser having at least one pressing surface is slidably received within the interior space of the guidance housing. A punch member sized to fit at least partially through the side opening is located adjacent to the pressing surface within the interior space. The advancement of the presser relative to the guidance housing causes the pressing surface to urge the punch through the side opening and through a wall of the tubular member.

[0010] In yet another aspect of the apparatus of the present invention, the guidance housing defines a hollow interior space and at least one side opening. The elongated presser slidably received within the interior space of the guidance housing includes a distal end, a flanged end, and at least one sloped pressing surface sloping toward the flanged end and the side opening in the guidance housing. A floating punch member is received within the interior space of the guidance housing and is placed in contact with the sloped pressing surface of the presser. The floating punch member is sized so that at least a portion of the punch member is receivable through the side opening. The advancement of the presser relative to the guidance housing causes the pressing surface to urge the floating punch through the side opening and through a sidewall of the tubular member.

[0011] The invention may also be embodied in a system provided in conjunction with the preferred apparatus. The system includes a pressurizable cylinder linked to the presser in the apparatus. A pump is also provided to pressurize the cylinder, and a clamping device is used to hold and reinforce at least a portion of the tubular member.

[0012] The invention may be further embodied in a method of forming an opening in the sidewall of a tubular member. The method includes the steps of inserting an elongated guidance housing into the tubular member, inserting a floating punch member into the interior space, and inserting an elongated presser into the interior space of the guidance housing. The presser includes at least one sloped pressing surface, wherein the insertion of the presser captures the punch member between the sloped pressing surface and the side opening of the guidance housing. The presser is then advanced relative to the guidance housing within the tubular member. This causes the pressing surface to push the floating punch through the side opening and through a sidewall of the tubular member.

[0013] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. The invention, together with further objects and attendant advantages, will best be understood by reference to the following detailed description, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a perspective exploded view of a first embodiment of the apparatus of the present invention.

[0015]FIG. 2 is an assembled perspective view showing the apparatus of FIG. 1.

[0016]FIG. 3 is a cutaway view of the apparatus of FIG. 1 showing the apparatus in use.

[0017]FIG. 4 is the same view of the apparatus as in FIG. 3, showing a flange being progressively formed.

[0018]FIG. 5 is the same view of the apparatus as in FIG. 4, showing a flange being progressively formed.

[0019]FIG. 6 is a schematic diagram showing the apparatus of FIG. 1 implemented in a system of the present invention.

[0020]FIG. 7 is a perspective view of a second preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Referring now to the drawings, in particular FIG. 1, a forming apparatus 10 includes a guidance housing 12, a presser 14, and a punch 16. In preferred embodiment, the guidance member 12 is formed from a tubular steel tube having a distal end 18 and a mounting end 20. Proximate to the mounting end 20, an annular mounting flange 22 is preferably integrated to the guidance member 12. The distal end of the guidance housing 12 preferably defines a front side opening 24 into the axially extending hollow space defined within the member 12.

[0022] An elongated opening 26 is defined proximate the distal end 18 of a guidance housing 12 axially along a cylindrical side of the tube. The opening 26 preferably includes a curved front end face 28 closest to the distal end 18. Side edges 30 extend axially along the housing 12 toward a rear edge 32, which is also preferably of a semicircular curve shape.

[0023] Presser 14 is preferably formed from solid steel cylindrical stock preferably about 0.442 inches in diameter. The circumference of the presser 14 is sized to fit closely within the interior circumference of the guidance housing 12. The presser 14 includes a distal end 40 and a rear end 42. Beginning at the distal end 40 of the presser 14 and extending rearwardly toward a center of the length of the cylinder is a flattened pressing surface 44 machined into the cylinder shape of the presser 14. Preferably, the pressing surface 44 is divided into a horizontal section 44 a and at least one ramped or wedged section 44 b. The horizontal section 44 a preferably is 0.5 inches in length and is shorter than the ramped section 44 b. An elongated, shallow guidance groove 46 is defined centrally along the surface sections 44 a and 44 b and extends substantially along the lengths of the surface sections. The groove is preferably 0.1 inches wide and defines an interior, cross-sectional radius of approximately 0.1 inches. The groove preferably extends approximately 2.0 inches along the horizontal axis. The ends of the slot 46 include semicircular edges 48 preferably approximately 0.05 inches in radius.

[0024] It has been found that the ramped or wedged surface section 44 b performs best when the surface 44 b is machined to an angle of 170 degrees with the horizontal plane along the axis of the presser 14. A tolerance of plus or minus 0.05 degrees has also been found to provide acceptable results for the presently preferred application. The ramped or wedged section 44 b preferably extends approximately 1.875 inches along the horizontal axis. Of course, these and other specific measurements may vary in accordance with the particular requirements of the application and are not meant to be limiting herein.

[0025] A second elongated positioning slot 50 extends diametrically through the cylinder 53 of the presser 14, and extends in axial alignment with the groove 46. The slot 50 extends within the area bounded by the surface section 44 b and the rear end 42 of the presser 14. Preferably, the slot 50 is about 0.167 inches wide and includes curved end portions 54 preferably having a radius of 0.08 inches. The remaining, non-machined portions of the presser 14 preferably form right cylindrical walls 58 which are sized to fit within the hollow bore of the guidance member 12. Thus, the presser 14 may be slidably received within the guidance member 12, and force applied longitudinally to the rear end 42 of the presser 14 relative to the guidance housing 12 forces the pressing surface sections 44 a and 44 b to move forwardly underneath the opening 26 in the guidance housing 12.

[0026] When the presser 14 is properly positioned within the guidance housing 12, an alignment pin 60 may be inserted through the cylinder 22 or the rear end of the guidance member 12 and at least partially through the slot 50 in the presser 14. The alignment pin 60 prevents rotation of the presser 14 relative to the guidance housing 12, yet allows for axial displacement of the presser 14 within the guidance housing 12. A range of extension and insertion of the presser 14 is thus allowed identical to the length of slot 50. Of course, other guidance mechanisms may be utilized. For example, keyed recesses and protrusions on either the sides of the presser 14 or the interior surface of the guidance housing 12 may be utilized to register the presser 14 with the housing 12. Other alternative structures will be apparent to those skilled in the art.

[0027] The assembled apparatus 10 including the presser 14 inserted within the board of the guidance member 12 is shown in FIG. 2. As shown best in FIG. 1, a punch 16, preferably a spherical metal ball bearing, may be dropped into the slot 26 for registration with the groove 46 and pressing surface sections 44 a and 44 b of the presser 14. The punch 16 also registers within the slot 26 and the interior of the guidance member 12. The round surface of the ball bearing punch 16 allows the punch 16 to rotate relative to the curved edge 28 as the presser 14 is advanced relative to the guidance housing 12. During this advancement, the punch 16 is gradually raised transversely out of the slot 26 as it is pushed by the gradually sloping, ramped surface section 44 b of the presser 14. The transverse advancement of the punch 16 is what is used to create openings or flanges.

[0028] The operation of the apparatus 10 is shown in FIGS. 3-5. Turning to FIG. 3, the cutaway illustration shows a tubular aluminum manifold pipe or tubular member 75 consisting of a tubular straight portion 76 and an elbow portion 77. A preformed opening 78 has preferably been drilled in the top of the straight portion 76. The tubular member 75 is preferably held in place by an external clamp 80 made of hardened tool steel. The clamp 80 preferably includes two halves split along a longitudinally extending face 82. A round opening 84 is provided at the top of the clamp which allows for alignment with the preformed opening 78 in the tubular member 75.

[0029] In the present example application, it is desired for an annular flange to be formed surrounding the preformed opening 78 in the tubular member 75. It is also desired that the flange be directed approximately 9 degrees from the normal transverse direction to allow custom installation of an angled branch connection to the member 75. The particular configuration of the clamp openings 84 assist in directing the flange in this orientation.

[0030] A forward edge 86 and a rearward edge 88 of the clamp opening 84 control the direction of flange formation. In particular, the rearward edge 88, at its point closest to elbow 77, includes a cross-sectional bent angle at approximately 10 degree deviation from vertical. The leading edge 86 includes a stepped tang formed in the edge as shown. In the preferred embodiment, an innermost edge 89 and an outermost edge 90 are formed of roughly equal thickness. The edges 89 and 90 are separated in the horizontal direction preferably by approximately 0.021 inches.

[0031] As shown in FIG. 3, the distal end of the apparatus 10 is inserted through an open end 74 of the tubing 75. Preferably, the leading edge 28 of the side opening 26 is aligned with the edge of the pre-formed opening 78 in the tubing 75. By sliding the presser 14 into the position as shown, the ball-bearing punch 16 may also be aligned with the pre-formed opening 78.

[0032] Gentle forward pressure P applied to the presser 14 in the direction of the arrow shown lodges the punch 16 against the edge 28 of the opening 26 as shown.

[0033] The completion of the flange forming operation around the preformed opening 78 is shown in FIGS. 4-5. Referring first to FIG. 4, increased pressure P2 is used to force the presser forward relative to the guidance housing 12. This results in the sloped pressing surface section 44 b urging the ball bearing punch 16 against the leading edge 28 of the side opening 26. The groove 46 in the sloped surface section 44 b keeps the bearing punch 16 centered on the pressing surface section 44 b to ensure that the punch 16 remains in the axial center of the opening 26 during the formation of the flange. The punch 16 is thus driven upwardly in the direction of the vertical arrow D. In this Figure, the beginning of the formation of flange 100 around the preformed opening 78 may be seen as the punch 16, which is slightly larger in circumference than the preformed opening 78, bears against the rim of the preformed opening 78 and bends the rim against the edges 88 and 86 of the clamp 80.

[0034] Turning now to FIG. 5, as pressure P2 continues to urge the presser 14 forwardly through the guidance housing 12, the ball bearing punch 16 is finally pushed through the preformed opening 78 in the tubing 75. This final urging of the widest diameter of the punch 16 urges the top edges of the newly formed annular flange 100 completely against the edge 88 and tang 90 of the clamp 80. This orientation of the edges 86 and 88 of the clamp forces the punch 16 to exit the clamp portion 80 in the adjusted direction D2, which is approximately 10 degrees from vertical. At this point, the ball bearing punch 16 may be removed and the guidance housing 12 and presser 14 may be withdrawn from the tube 75.

[0035] Turning now to FIG. 6, a system for utilizing the apparatus 10 is shown in a schematic diagram. In particular, the apparatus 10 is shown including guidance housing 12, a presser 14, a punch 16 and a clamp 80. In order to apply the proper amount of force to move the presser 14 forwardly within the guidance housing 12, an hydraulic cylinder 200 may be provided as shown. The cylinder 200 includes a projecting piston 210 which is preferably linked to a rear end 42 of the presser 14. Pressurization of the cylinder 200 may be accomplished by pumping either fluid or air from a hydraulic pump 220 into the cylinder 200. The pressurization forces the piston 210 forward, which in turn forces the presser 14 forward. In the preferred embodiments, the preferred force must be applied along the axial direction of the presser 14 to form the flange in the stainless steel manifold pipe is approximately 380 in-lbs.

[0036]FIG. 7 shows a second preferred embodiment of the invention. In particular, an elongated guidance housing 312 is shown having two separate side openings 326. Aligned with these openings are dual ramped or wedged presser surfaces 344 and 345 having ramped sections 344 b and 345 b, respectively, which are integrally formed into a single elongated presser 314. The apparatus as shown in FIG. 7 preferably operates in substantially identical fashion to the apparatus shown in FIGS. 1-5, although a separate punch may be utilized within each of the dual openings 326 to form simultaneously a flange within each of two separate preformed openings.

[0037] The above preferred embodiments of the invention have been configured for use in forming openings in tubular members. It should be noted, however, that the invention may be modified to form openings in any hard-to-reach places, even in flat walls. For example, when it is required to form an opening perpendicularly to a sheet of metal in a difficult-to-access area, such as between parallel walls spaced only inches apart, the invention may be modified accordingly. In this regard, the guidance housing 12 may include means for holding the guidance housing 12 securely against a wall so that its side opening 26 is positioned against the wall. Such holding means may be implemented using suction technology or electromagnets, for example. Once the guidance housing 12 is secured against the wall, the presser 14 may be utilized to urge the punch 16 through the wall as described above. This type of configuration would allow the forming of openings without the necessity for space-consuming drill bits and their associated motor structures.

[0038] Of course, it should be understood that a wide range of changes and modifications can be made to the embodiments described above. For example, the punch used to enlarge the preformed opening need not be a ball bearing. In the alternative, the punch may comprise a flap hinged to an inside of the guidance housing 12 and configured to be urged upwardly of the guidance housing through the use of a forwardly thrusting piston or presser configuration. Furthermore, the guidance housing and the presser need not be cylindrical in shape, and may comprise open interfacing cross-sectional pieces. In addition, it is important to note that the present apparatus need not be utilized solely to form flanges around pre-formed openings. Indeed, the apparatus may be used to form new openings by applying sufficient force to the punch to force it through a solid wall of an object. The apparatus is also useful for forming openings in any wall in a difficult-to-access area, as noted above. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it be understood that it is the following claims, including all equivalents, which are intended to define the scope of this invention. 

1. An apparatus for creating a flange around a preformed opening in a wall of a tubular member, said apparatus comprising: an elongated guidance housing adapted to fit within said tubular member, said guidance housing defining a hollow interior space and at least one side opening; an elongated presser slidably received within said interior space of said guidance housing, said presser having at least one pressing surface; and a punch member located adjacent said pressing surface within said interior space, said member being sized to fit at least partially through said side opening and at least partially through said preformed opening; wherein the advancement of said presser relative to said guidance housing causes said pressing surface to push said punch through said side opening and through said preformed opening, the movement of said punch thereby forming an outwardly upstanding annular flange extending around said preformed opening.
 2. The apparatus of claim 1 further comprising a clamping die to said punch member in a predetermined direction away from said preformed opening to form a directed flange around said preformed opening.
 3. The apparatus of claim 2 wherein said punch member further comprises a ball bearing sized to fit at least partially through said side opening of said elongated guidance housing.
 4. The apparatus of claim 2 wherein at least a portion of said pressing surface of said elongated presser further comprises a wedge shape, wherein said surface wedges said punch member against a portion of said elongated guidance housing.
 5. The apparatus of claim 4 further comprising a tang edge formed along an interior edge surface of said side opening, wherein said at least a portion of said pressing surface urges said punch member against said tang edge.
 6. A system for creating a flange around a preformed circular opening in a wall of a tubular member, said apparatus comprising: an elongated guidance housing adapted to fit within said tubular member, said guidance housing defining a hollow interior space and at least one side opening; an elongated presser slidably received within said interior space of said guidance housing, said presser having at least one pressing surface; at least one ball bearing located adjacent said pressing surface within said interior space, said member being sized to fit at least partially through said side opening and at least partially through said preformed opening; means for advancing said presser within said guidance housing, said means including a pressurizable cylinder linked to a pump for pressurizing said cylinder, said cylinder incorporating a slidable piston connected to said presser; and a clamp rigidly enclosing and reinforcing at least an exterior portion of said tubular member around said preformed opening; wherein the advancement of said presser relative to said guidance housing causes said at least one pressing surface to push said bearing through said side opening and through said preformed opening, the movement of said bearing through said opening thereby forming an outwardly upstanding annular flange extending around said preformed opening.
 7. An apparatus for forming an opening in a wall of a tubular member, said apparatus comprising: an elongated guidance housing adapted to fit within said tubular member, said guidance housing defining a hollow interior space and at least one side opening; an elongated presser slidably received within said interior space of said guidance housing, said presser having at least one pressing surface; and a punch member located adjacent said pressing surface within said interior space, said member being sized to fit at least partially through said side opening; wherein the advancement of said presser relative to said guidance housing causes said pressing surface to urge said punch through said side opening and through a wall of said tubular member.
 8. An apparatus for creating a flanged opening in a wall, said apparatus comprising: an elongated guidance housing adapted to be positioned against said wall, said guidance housing defining a hollow interior space and at least one side opening; an elongated presser slidably received within said interior space of said guidance housing, said presser having at least one pressing surface; and a punch member located adjacent said pressing surface within said interior space, said member being sized to fit at least partially through said side opening and at least partially through said preformed opening; wherein the advancement of said presser relative to said guidance housing causes said pressing surface to push said punch through said side opening and through said wall to create an opening, the movement of said punch thereby forming an outwardly upstanding annular flange extending around said opening.
 9. The apparatus of claim 8 further comprising means for removably securing said guidance housing against said wall.
 10. The apparatus of claim 9 wherein said means further comprises a suction mechanism for attachment to said wall.
 11. The apparatus of claim 9 wherein said means further comprises an electromagnet.
 12. An apparatus for forming an opening in the sidewall of a tubular member, said apparatus comprising: an elongated guidance housing adapted to fit within said tubular member, said guidance housing defining a hollow interior space and at least one side opening in said housing; an elongated presser slidably received within said interior space of said guidance housing, said presser having a distal end and a flanged end, said presser having at least one sloped pressing surface sloping toward said flanged end and said side opening in said guidance housing; and a floating punch member received within said interior space of said guidance housing and in contact with said sloped pressing surface of said presser, said floating punch member being sized so that at least a portion of said punch member is receivable through said side opening; wherein the advancement of said presser relative to said guidance housing causes said pressing surface to urge said floating punch through said side opening and through a sidewall of said tubular member.
 13. The apparatus of claim 12 wherein said at least one pressing surface on said elongated presser forms a wedge shape.
 14. The apparatus of claim 13 wherein said at least one side opening in said elongated guidance housing is located adjacent a distal end of said housing.
 15. The apparatus of claim 14 wherein said at least one side opening in said elongated guidance housing is located on a curved sidewall of said housing.
 16. The apparatus of claim 15 further comprising at least one groove formed in said at least one pressing surface of said elongated presser to guide said floating punch member along the center of said sloped pressing surface during the advancement of said presser relative to said guidance housing.
 17. The apparatus of claim 16 further comprising an alignment pin extending inwardly from an inside surface of said guidance housing and into a groove defined on a portion of said presser, said groove and pin cooperating to prevent rotation of said presser within said guidance housing.
 18. The apparatus of claim 17 wherein said punch member further comprises a ball bearing.
 19. The apparatus of claim 18 wherein said elongated guidance housing further comprises a hollow right cylindrical tube, and at least a portion of said elongated presser comprises a cylinder adapted to closely fit within said guidance housing.
 20. A method of forming an opening in the sidewall of a tubular member, said method comprising the steps of: inserting an elongated guidance housing into said tubular member, said guidance housing defining a hollow interior space and at least one side opening in said housing; inserting a floating punch member into said interior space; inserting an elongated presser into said interior space of said guidance housing, said presser having at least one sloped pressing surface, said insertion of said presser capturing said punch member between said sloped pressing surface and said side opening of said guidance housing; and advancing said presser relative to said guidance housing to cause said at least one pressing surface to push said floating punch through said side opening and through a sidewall of said tubular member. 